Shipyard Safety Manual

OSHA Shipyard Requirements

Federal OSHA regulates shipyard employment primarily under 29 CFR Part 1915 — Occupational Safety and Health Standards for Shipyard Employment.

Shipyard employment includes:

• Ship repairing.
• Shipbuilding.
• Shipbreaking.
• Related employment.

Part 1915 contains requirements addressing major shipyard hazards including:

• Confined and enclosed spaces.
• Toxic and hazardous atmospheres.
• Surface preparation.
• Painting and coating.
• Welding, cutting, and heating.
• Scaffolds.
• Ladders.
• Access.
• Working surfaces.
• Material handling.
• Rigging.
• Tools.
• Machinery.
• Electrical hazards.
• Personal Protective Equipment.
• Fire protection.
• Hazardous-energy control.
• General working conditions.

Other OSHA requirements may also apply according to the work being performed.

Types of Shipyard Operations

Shipyard work varies substantially according to the facility and project.

Operations may include:

• New ship construction.
• Vessel repair.
• Vessel overhaul.
• Dry-dock operations.
• Ship conversion.
• Fabrication.
• Structural steel work.
• Pipefitting.
• Welding.
• Cutting.
• Painting.
• Blasting.
• Electrical work.
• Machinery repair.
• Tank cleaning.
• Shipbreaking.
• Vessel dismantling.
• Material handling.
• Crane and rigging operations.

The safety programs included in the manual should reflect the operations actually performed.

What Should a Shipyard Safety Manual Include?

Depending on operations, a Shipyard Safety Manual may address:

• Shipyard safety responsibilities.
• Hazard assessments.
• Job Safety Analysis.
• Confined and enclosed spaces.
• Hazardous atmospheres.
• Shipyard competent persons.
• Marine chemists.
• Hot Work.
• Welding, cutting, and heating.
• Fire prevention.
• Fire watches.
• Fire response.
• Scaffolds.
• Fall protection.
• Ladders and access.
• Shipyard Lockout/Tags-plus.
• Electrical safety.
• Machinery and piping systems.
• Cranes and derricks.
• Rigging.
• Material handling.
• Surface preparation.
• Abrasive blasting.
• Painting and coating.
• Hazard Communication.
• Respiratory protection.
• Personal Protective Equipment.
• Occupational health hazards.
• Emergency procedures.

Programs should be selected according to the employer’s actual shipyard operations and employee exposures.

Shipyard Safety Program

An effective Shipyard Safety Program establishes responsibilities and procedures for controlling vessel, machinery, atmospheric, fire, fall, chemical, material-handling, and other hazards.

Management should provide employees with safe equipment, appropriate PPE, training, supervision, hazard controls, emergency resources, and safe work procedures.

Managers, supervisors, and designated safety personnel should:

• Identify and evaluate shipyard hazards.
• Maintain applicable written safety programs.
• Coordinate vessel and shoreside activities.
• Establish safe work procedures.
• Maintain equipment and safeguards.
• Control hazardous energy.
• Evaluate atmospheric hazards.
• Coordinate Hot Work.
• Provide fire protection.
• Provide appropriate PPE.
• Correct unsafe conditions.
• Investigate incidents.
• Provide employee training.
• Maintain applicable records.

Employees should follow established procedures, use required PPE, maintain safe work areas, follow hazardous-energy and Hot Work controls, and promptly report unsafe conditions, hazardous atmospheres, damaged equipment, fires, injuries, and other hazards.

Shipyard Hazard Assessments

Hazard assessments should consider each work area and task.

Potential areas include:

• Vessel decks.
• Tanks.
• Compartments.
• Engine rooms.
• Machinery spaces.
• Dry docks.
• Shipways.
• Fabrication shops.
• Paint areas.
• Blast areas.
• Scaffolds.
• Crane areas.
• Material-storage areas.
• Maintenance shops.

Potential hazards may include:

• Oxygen deficiency.
• Toxic atmospheres.
• Flammable atmospheres.
• Fire and explosion.
• Welding fumes.
• Falls.
• Falling objects.
• Suspended loads.
• Electrical energy.
• Hazardous energy.
• Chemicals.
• Noise.
• Heat.
• Heavy material handling.

Assessments should be reviewed as vessel conditions and work activities change.

Job Safety Analysis (JSA/JHA)

A JSA/JHA may be used to evaluate higher-risk shipyard activities.

Potential JSAs/JHAs may address:

• Confined-space entry.
• Tank cleaning.
• Hot Work.
• Welding and cutting.
• Abrasive blasting.
• Spray painting.
• Scaffold erection.
• Work at heights.
• Crane operations.
• Rigging.
• Machinery maintenance.
• Electrical work.
• Shipbreaking.
• Heavy-component removal.

The analysis should identify job steps, hazards, controls, PPE, and employee responsibilities.

Shipyard Competent Person

Certain shipyard operations require evaluations or determinations by a shipyard competent person.

The competent person should have the knowledge and ability necessary to perform assigned duties and recognize relevant hazards.

Depending on the work, duties may involve:

• Atmospheric testing.
• Space evaluation.
• Maintaining required conditions.
• Inspecting spaces.
• Determining when additional testing is necessary.
• Maintaining applicable records.

Employees should understand when competent-person authorization or evaluation is required.

Marine Chemist

Certain shipyard work requires certification or evaluation by a Marine Chemist or other qualified individual as specified by applicable requirements.

This can be particularly important before Hot Work involving:

• Tanks.
• Compartments.
• Spaces that contained flammable materials.
• Adjacent spaces.
• Piping.
• Other hazardous locations.

Required certificates and conditions should be followed.

Confined and Enclosed Spaces

Shipyards may contain numerous confined or enclosed spaces, including:

• Tanks.
• Voids.
• Compartments.
• Double bottoms.
• Cofferdams.
• Engine spaces.
• Pits.
• Other vessel spaces.

Potential hazards include:

• Oxygen deficiency.
• Oxygen enrichment.
• Toxic atmospheres.
• Flammable atmospheres.
• Residual chemicals.
• Welding fumes.
• Limited access.

Employees should not enter spaces until applicable evaluation and entry requirements have been completed.

Atmospheric Testing

Atmospheric testing should be performed where required before employees enter or perform work in affected spaces.

Testing may evaluate:

• Oxygen concentration.
• Flammable vapors.
• Toxic contaminants.

Testing should be performed with appropriate instruments by authorized personnel.

Conditions should be retested when necessary.

Oxygen-Deficient Atmospheres

Employees should not enter oxygen-deficient atmospheres without required controls and protection.

Potential causes may include:

• Rusting.
• Inert gases.
• Welding.
• Chemical reactions.
• Displacement by other gases.

Ventilation should be used where appropriate.

Oxygen-Enriched Atmospheres

Oxygen-enriched atmospheres can significantly increase fire risk.

Oxygen should never be used for ventilation.

Leaks involving oxygen equipment should be corrected promptly.

Flammable Atmospheres

Hot Work and other ignition sources should be prohibited where flammable atmospheres exceed applicable safe conditions.

Testing and controls should consider:

• Residual fuel.
• Solvents.
• Coatings.
• Cargo residues.
• Gas cylinders.
• Piping systems.

Required safe conditions should be maintained throughout the work.

Toxic Atmospheres

Potential toxic contaminants may include:

• Welding fumes.
• Solvent vapors.
• Coating components.
• Hydrogen sulfide.
• Carbon monoxide.
• Metals.
• Other process contaminants.

Exposure should be evaluated according to the work and vessel history.

Ventilation

Mechanical or natural ventilation may be necessary to control:

• Welding fumes.
• Solvent vapors.
• Toxic gases.
• Oxygen deficiency.
• Heat.
• Other airborne contaminants.

Ventilation equipment should be arranged so contaminants are effectively removed without creating additional hazards.

Confined-Space Rescue

Emergency planning should address employees working in confined or enclosed spaces.

Rescue arrangements should consider:

• Space configuration.
• Access.
• Atmospheric hazards.
• Retrieval.
• Communication.
• Rescue equipment.
• Emergency medical response.

Employees should not make uncontrolled rescue entries.

Hot Work

Welding, cutting, brazing, heating, and similar operations are common throughout shipyard employment.

Hot Work procedures should address:

• Fire hazards.
• Flammable atmospheres.
• Combustible materials.
• Adjacent spaces.
• Tanks.
• Piping.
• Coatings.
• Gas cylinders.
• Ventilation.
• Fire watches.

Hot Work should not begin until applicable precautions have been completed.

Hot Work Authorization

Before Hot Work begins, the work area should be evaluated to determine:

• Fire potential.
• Atmospheric hazards.
• Combustible materials.
• Adjacent-space hazards.
• Required ventilation.
• Required fire watch.
• Required certification.

Conditions should be maintained throughout the work.

Hot Work in Confined or Enclosed Spaces

Hot Work inside tanks, compartments, or other enclosed spaces may introduce:

• Welding fumes.
• Oxygen depletion.
• Toxic contaminants.
• Fire.
• Explosion.
• Heat stress.

Applicable atmospheric testing, ventilation, authorization, and fire-protection requirements should be followed.

Adjacent Spaces

Heat, sparks, slag, and hot metal can create fire hazards on the opposite side of:

• Bulkheads.
• Decks.
• Partitions.
• Other structures.

Adjacent spaces should be evaluated and protected.

Fire watches should be assigned where required.

Fire Watch

A fire watch should be posted where required by the hazards and applicable shipyard fire-protection requirements.

Fire-watch personnel should:

• Understand assigned duties.
• Remain alert for fire.
• Have appropriate extinguishing equipment available.
• Maintain communication.
• Stop work when necessary.
• Initiate emergency response.

Fire-watch personnel should not be assigned duties that interfere with their fire-watch responsibilities.

Shipyard Fire Safety Plan

Shipyard employers should maintain a written fire safety plan where required.

The plan should address applicable:

• Fire hazards.
• Alarm systems.
• Employee responsibilities.
• Evacuation.
• Fire-response organizations.
• Fire-protection equipment.
• Training.

Affected employees should understand the portions of the plan relevant to their work.

Fire Prevention

Shipyard fire hazards may involve:

• Hot Work.
• Fuel.
• Paint.
• Solvents.
• Oxygen.
• Acetylene.
• Combustible vessel materials.
• Temporary structures.
• Electrical equipment.

Combustible materials should be controlled and ignition sources managed.

Fire Response

Shipyard emergency planning should clearly identify whether employees:

• Evacuate.
• Use portable extinguishers.
• Participate in an internal fire brigade.
• Rely on outside fire-response organizations.

Employees should perform only the emergency duties for which they are trained and equipped.

Fixed Fire-Extinguishing Systems

Vessels may contain fixed fire-extinguishing systems capable of releasing agents that can create dangerous atmospheres.

Before employees work in affected spaces, procedures should prevent inadvertent system activation where required.

Employees should understand alarms and evacuation requirements.

Welding and Cutting

Welding and cutting may expose employees to:

• Burns.
• Electric shock.
• Fire.
• Explosion.
• Ultraviolet radiation.
• Welding fumes.
• Toxic metals.
• Compressed gases.

Employees should receive training appropriate to the processes they perform.

Welding Fumes

Welding fumes can contain hazardous metals and gases depending on:

• Base metal.
• Coating.
• Consumable.
• Welding process.
• Ventilation.
• Work location.

Potential exposures should be evaluated rather than assuming all welding fumes present the same hazard.

Coated Surfaces

Welding, cutting, or heating coated metal can release hazardous decomposition products.

Coatings should be identified and evaluated before work begins.

Controls may include:

• Coating removal.
• Ventilation.
• Respiratory protection.
• Exposure monitoring.

Lead — When Applicable

Shipyard employees may encounter lead in:

• Paint.
• Coatings.
• Structural components.
• Repair work.
• Shipbreaking.

Potential lead exposure should be evaluated before disturbing lead-containing materials.

Applicable exposure controls, PPE, hygiene, training, medical surveillance, and respiratory protection should be implemented where required.

Hexavalent Chromium — When Applicable

Hot Work involving stainless steel or chromium-containing materials can generate hexavalent chromium.

Where potential exposure exists, employers should evaluate employee exposure and implement required controls.

Cadmium — When Applicable

Cadmium may be encountered in certain:

• Coatings.
• Alloys.
• Plating.
• Welding operations.

Employees should not assume coated or plated materials are safe to weld or cut without evaluation.

Beryllium — When Applicable

Certain specialty alloys may contain beryllium.

Where employees may disturb beryllium-containing materials, applicable exposure requirements should be evaluated.

Asbestos — When Applicable

Older vessels may contain asbestos-containing materials in:

• Insulation.
• Pipe covering.
• Gaskets.
• Panels.
• Machinery spaces.
• Other components.

Materials should be evaluated before disturbance.

Applicable asbestos controls should be implemented where required.

Surface Preparation

Shipyard surface preparation may involve:

• Abrasive blasting.
• Grinding.
• Needle gunning.
• Sanding.
• Scraping.
• Chemical stripping.

Potential hazards include:

• Dust.
• Noise.
• Flying particles.
• Toxic coatings.
• Respiratory exposure.
• Ergonomic stress.

Abrasive Blasting

Abrasive blasting may create high concentrations of airborne dust and coating contaminants.

Procedures should address:

• Blast media.
• Existing coatings.
• Ventilation.
• Respiratory protection.
• Hearing protection.
• Eye and face protection.
• Employee isolation.

Blasting equipment should be inspected and maintained.

Silica — When Applicable

Certain abrasive materials or disturbed products may present respirable crystalline silica hazards.

Employers should evaluate the materials and exposure rather than assuming all abrasive blasting creates the same silica exposure.

Painting and Coating

Shipyard painting may involve:

• Solvent-based coatings.
• Epoxies.
• Polyurethanes.
• Antifouling coatings.
• Primers.
• Specialty marine coatings.

Potential hazards include:

• Toxic vapors.
• Skin exposure.
• Fire.
• Explosion.
• Respiratory hazards.

Controls should reflect the actual product and application method.

Spray Painting

Spray application can increase airborne chemical exposure and fire hazards.

Procedures should address:

• Ventilation.
• Ignition sources.
• PPE.
• Respiratory protection.
• Equipment grounding where applicable.
• Overspray.

Employees should follow Safety Data Sheet precautions.

Isocyanates — When Applicable

Some polyurethane coatings may contain isocyanates.

Where such products are used, exposure should be evaluated and appropriate engineering controls, PPE, respiratory protection, training, and work practices implemented.

Solvents

Solvents may be used for:

• Painting.
• Cleaning.
• Degreasing.
• Surface preparation.
• Adhesive work.

Potential hazards include:

• Inhalation.
• Skin absorption.
• Eye contact.
• Fire.
• Central nervous system effects.

The specific solvent should be identified and evaluated.

Hazard Communication

The Hazard Communication Program should address hazardous chemicals employees may encounter during shipyard work.

Applicable elements may include:

• Chemical inventory.
• Labels.
• Safety Data Sheets.
• Employee training.
• Non-routine tasks.
• Contractor chemicals.

Employees should know how to obtain chemical hazard information.

Shipbreaking

Shipbreaking can involve dismantling vessels containing unknown or legacy hazards.

Potential hazards include:

• Structural instability.
• Falling material.
• Hazardous energy.
• Residual fuel.
• Hazardous atmospheres.
• Asbestos.
• Lead.
• PCBs.
• Heavy metals.
• Cutting operations.
• Suspended loads.

Hazards should be evaluated before dismantling begins.

Shipbreaking Survey and Planning

Before dismantling, the employer should obtain available information about:

• Vessel construction.
• Fuel systems.
• Tanks.
• Piping.
• Electrical systems.
• Hazardous materials.
• Structural condition.

Work should be sequenced to maintain structural stability and employee protection.

Structural Dismantling

Shipbreaking can alter the structural integrity of a vessel.

Employees should not work beneath unsupported sections or in areas where cutting can cause uncontrolled movement.

Cut sections should be supported, rigged, or otherwise controlled before separation.

Residual Fuel and Chemicals

Tanks, pipes, machinery, and compartments may contain residual:

• Fuel.
• Oil.
• Chemicals.
• Vapors.
• Sludge.

Systems should be evaluated, drained, cleaned, isolated, or otherwise controlled before cutting or dismantling.

Scaffolds

Shipyard work frequently requires scaffolds around hulls, structures, tanks, and equipment.

Scaffolds should be:

• Properly constructed.
• Adequately supported.
• Inspected.
• Safely accessed.
• Maintained.

Employees should not use incomplete or damaged scaffolds.

Scaffold Access

Safe access should be provided to scaffold platforms.

Employees should not climb:

• Cross braces.
• Improvised supports.
• Unapproved structural members.

Access ladders and stairways should be maintained.

Scaffold Platforms

Platforms should provide appropriate:

• Width.
• Planking.
• Support.
• Guarding.
• Access.

Loose material should not be allowed to create trip or falling-object hazards.

Fall Protection

Employees may be exposed to falls from:

• Vessel decks.
• Scaffolds.
• Dry docks.
• Shipways.
• Staging.
• Openings.
• Elevated structures.

Applicable fall-protection requirements should be followed.

Deck Openings

Open hatches, manholes, and other deck openings should be protected as required.

Employees should not remove covers or guards unless necessary for work and appropriate alternative protection is provided.

Ladders

Ladders should be:

• Appropriate for the task.
• Inspected.
• Properly positioned.
• Maintained.

Employees should not use damaged ladders.

Vessel Access

Safe access should be provided between:

• Shore and vessel.
• Dock and vessel.
• Dry dock and vessel.
• Different vessel elevations.

Gangways, ladders, ramps, or other access systems should be maintained in safe condition.

Gangways

Gangways should be:

• Adequately supported.
• Secured.
• Maintained.
• Appropriately guarded.
• Kept clear.

Employees should not use damaged or unstable gangways.

Dry Dock Safety

Dry-dock operations can expose employees to:

• Falls.
• Vessel movement.
• Blocks.
• Cranes.
• Confined spaces.
• Material handling.
• Water hazards.

Work should be coordinated with docking and vessel-support conditions.

Dry-Dock Access

Safe access should be provided to dry-dock work areas.

Stairs, ladders, walkways, and platforms should be maintained free of unnecessary obstructions.

Working Over or Near Water

Shipyard employees may work on docks, floats, vessels, or other locations where falling into water presents a hazard.

Appropriate lifesaving equipment and personal flotation devices should be provided where required.

Personal Flotation Devices

Where employees are exposed to drowning hazards, appropriate PFDs should be provided and used as required.

PFDs should be:

• Suitable for the work.
• Properly fitted.
• Maintained.
• Inspected.

Damaged equipment should be removed from service.

Lockout/Tags-Plus

Shipyard employment has specific hazardous-energy requirements commonly referred to as Lockout/Tags-plus.

The program should protect employees from energization or startup of machinery, equipment, or systems and from release of hazardous energy during servicing.

The program should reflect applicable shipyard requirements rather than relying solely on a generic General Industry Lockout/Tagout procedure.

Lockout/Tags-Plus Program

Where required, the employer should establish and implement a written Lockout/Tags-plus program.

The program should address:

• Employee responsibilities.
• Energy-control procedures.
• Lockout systems.
• Tags-plus systems.
• Verification.
• Coordination.
• Training.
• Inspections.
• Shift changes.

Employees should understand the system used at the facility.

Lockout vs. Tags-Plus

Lockout should be used where an energy-isolating device is capable of being locked unless applicable requirements allow another system.

Where a tags-plus system is used, additional measures should provide equivalent protection as required.

A warning tag alone is not the entire protective system.

Energy Isolation

Potential shipyard energy sources include:

• Electrical.
• Mechanical.
• Hydraulic.
• Pneumatic.
• Steam.
• Pressure.
• Gravity.
• Thermal.
• Vessel systems.

Employees should identify and isolate all hazardous energy before covered servicing begins.

Verification

Before work begins, authorized employees should verify that isolation and de-energization have been accomplished.

Control switches alone should not be treated as energy-isolating devices.

Group Lockout/Tags-Plus

Complex shipyard projects may involve multiple employees, crafts, contractors, and shifts.

Group procedures should provide each authorized employee with appropriate protection throughout the work.

Responsibility for the overall operation should be clearly assigned.

Shift Changes

Procedures should maintain continuous protection when work extends across shift changes.

Lockout or tags-plus protection should not be interrupted during personnel transitions.

Machinery and Piping Systems

Work involving vessel machinery or piping may expose employees to:

• Pressure.
• Steam.
• Chemicals.
• Fuel.
• Hot liquids.
• Mechanical movement.

Systems should be appropriately isolated before employees begin covered work.

Piping Isolation

Piping systems may require:

• Valve closure.
• Lockout.
• Tags-plus.
• Blanking.
• Blinding.
• Disconnecting.
• Draining.
• Venting.

The isolation method should reflect the system and hazard.

Pressure Vessels

Pressure vessels should be serviced only after hazardous pressure, temperature, and material have been controlled.

Employees should not open pressure systems until a safe condition has been verified.

Electrical Safety

Shipyard electrical hazards may involve:

• Vessel systems.
• Shore power.
• Temporary power.
• Welding equipment.
• Portable tools.
• Extension cords.
• Lighting.

Electrical equipment should be maintained in safe condition.

Electrical work should be performed only by appropriately qualified employees.

Shore Power

Connecting or disconnecting shore power can expose employees to significant electrical hazards.

Procedures should address:

• Equipment condition.
• Connection sequence.
• De-energization.
• Grounding.
• Employee qualification.

Damaged equipment should not be used.

Temporary Electrical Systems

Temporary electrical systems should be installed and maintained to protect employees from:

• Shock.
• Damaged conductors.
• Wet conditions.
• Improper grounding.
• Physical damage.

Temporary cords should be routed to reduce trip and damage hazards.

Portable Lighting

Lighting used in confined or hazardous spaces should be appropriate for the environment.

Equipment should be protected from damage and selected according to atmospheric hazards where applicable.

Cranes and Derricks

Shipyards may use cranes and derricks for:

• Structural sections.
• Machinery.
• Steel plate.
• Equipment.
• Vessel components.
• Scrap.

Operations should address:

• Equipment capacity.
• Load control.
• Communication.
• Employee clearance.
• Rigging.
• Inspection.

Employees should remain clear of suspended loads.

Rigging

Rigging equipment may include:

• Wire rope.
• Slings.
• Chains.
• Shackles.
• Hooks.
• Lifting beams.
• Plate clamps.

Equipment should be appropriate for the load and inspected before use as required.

Defective rigging should be removed from service.

Material Handling

Shipyard materials may include:

• Steel plate.
• Pipe.
• Machinery.
• Structural members.
• Equipment.
• Scrap.
• Gas cylinders.

Material should be stored and handled to prevent:

• Falling.
• Rolling.
• Sliding.
• Collapse.

Mechanical assistance should be used where appropriate.

Steel Plate Handling

Large steel plate can create severe crushing and struck-by hazards.

Employees should remain clear of:

• Suspended plate.
• Unstable plate.
• Pinch points.
• Potential fall paths.

Plate clamps and other lifting devices should be used within their limitations.

Compressed Gas Cylinders

Shipyards commonly use oxygen, fuel gas, and other compressed gases.

Cylinders should be:

• Secured.
• Protected from damage.
• Stored appropriately.
• Kept away from incompatible hazards.

Valves, regulators, hoses, and fittings should be maintained.

Oxygen and Fuel Gas

Oxygen and fuel-gas systems should be handled carefully.

Employees should:

• Use approved equipment.
• Inspect hoses.
• Keep fittings clean.
• Control leaks.
• Close valves when required.

Oxygen should not be used as a substitute for compressed air or ventilation.

Tools

Hand and power tools should be selected and maintained for the work performed.

Employees should inspect tools and report:

• Missing guards.
• Damaged cords.
• Defective switches.
• Cracked grinding wheels.
• Damaged pneumatic hoses.

Defective tools should be removed from service.

Grinding

Grinding operations may expose employees to:

• Flying particles.
• Sparks.
• Noise.
• Wheel failure.
• Dust.
• Ergonomic stress.

Guards should remain installed and appropriate eye and face protection should be used.

Pneumatic Tools

Pneumatic tools should be connected using appropriate fittings and hose restraints where required.

Employees should not direct compressed air at themselves or coworkers.

Personal Protective Equipment

PPE should be selected according to the hazard assessment.

Depending on work performed, PPE may include:

• Hard hats.
• Safety glasses.
• Goggles.
• Face shields.
• Welding helmets.
• Protective footwear.
• Gloves.
• Hearing protection.
• Respiratory protection.
• Fall protection.
• Personal flotation devices.
• Chemical protective clothing.

Employees should understand PPE use and limitations.

Respiratory Protection

Shipyard work can create substantial respiratory hazards.

Where respirators are required, the employer should maintain an appropriate Respiratory Protection Program.

Applicable elements may include:

• Exposure evaluation.
• Respirator selection.
• Medical evaluation.
• Fit testing.
• Training.
• Inspection.
• Maintenance.
• Program evaluation.

Hearing Conservation

Potential shipyard noise sources include:

• Abrasive blasting.
• Grinding.
• Chipping.
• Welding.
• Machinery.
• Pneumatic tools.
• Fabrication equipment.

Employee noise exposure should be evaluated.

Required Hearing Conservation measures should be implemented where applicable thresholds are reached.

Heat Stress

Employees may work:

• Inside vessels.
• In confined spaces.
• Near Hot Work.
• Outdoors.
• In protective clothing.

Heat-illness prevention should consider:

• Temperature.
• Humidity.
• Radiant heat.
• Workload.
• PPE.
• Acclimatization.
• Hydration.
• Rest and cooling.

Housekeeping

Shipyard work areas should be maintained to reduce:

• Trips.
• Falls.
• Fire hazards.
• Blocked access.
• Material-handling hazards.

Employees should appropriately control:

• Welding leads.
• Hoses.
• Cords.
• Scrap.
• Tools.
• Debris.
• Materials.

Slips, Trips and Falls

Potential hazards may include:

• Wet decks.
• Oil.
• Hoses.
• Welding leads.
• Temporary power cords.
• Uneven surfaces.
• Openings.

Access routes should be kept as clear as practical.

Illumination

Adequate lighting should be provided for employees to safely perform work and travel through shipyard areas.

Temporary lighting should be protected from damage and suitable for the environment.

Sanitation

Shipyard employees should have access to appropriate:

• Drinking water.
• Toilet facilities.
• Washing facilities.

Additional hygiene facilities may be required where employees work with hazardous substances.

Medical Services and First Aid

Shipyard employers should provide medical services and first-aid capabilities appropriate to their operations.

Employees should know:

• How to obtain assistance.
• Emergency communication methods.
• First-aid locations.
• Reporting procedures.

Emergency Action Plan

Emergency procedures should reflect the shipyard’s operations.

Potential emergencies may include:

• Fire.
• Explosion.
• Toxic release.
• Confined-space emergency.
• Vessel flooding.
• Structural failure.
• Severe weather.
• Medical emergency.

Employees should understand alarms, evacuation routes, assembly locations, and assigned responsibilities.

Vessel Evacuation

Emergency planning should consider employees working:

• Below deck.
• In tanks.
• On scaffolds.
• In machinery spaces.
• In remote vessel compartments.

Evacuation routes should remain usable throughout the work.

Severe Weather

Shipyard operations may be affected by:

• High winds.
• Lightning.
• Heavy rain.
• Extreme heat.
• Cold.
• Storm conditions.

Cranes, scaffolds, elevated work, vessels, and outdoor operations should be evaluated when severe weather develops.

Contractor Safety

Shipyard projects may involve numerous employers working simultaneously.

Coordination should address:

• Hazardous energy.
• Hot Work.
• Confined spaces.
• Fire protection.
• Scaffolds.
• Cranes.
• Electrical work.
• Chemical use.
• Emergency procedures.

Employers should communicate hazards that can affect other employees.

Multi-Employer Worksites

Shipyard work often involves:

• Shipyard employees.
• Vessel owners.
• Contractors.
• Subcontractors.
• Specialty trades.

Responsibilities should be coordinated so one employer’s work does not create uncontrolled hazards for another employer’s employees.

Incident Reporting

Employees should promptly report:

• Injuries.
• Near misses.
• Fires.
• Hazardous atmospheres.
• Lockout/Tags-plus failures.
• Falls.
• Equipment incidents.
• Chemical exposures.
• Unsafe conditions.

Prompt reporting allows hazards to be investigated and corrected.

Incident Investigation

Significant incidents should be investigated to identify:

• Immediate causes.
• Contributing factors.
• Root causes.
• Corrective actions.

Investigations may consider:

• Work planning.
• Atmospheric testing.
• Hot Work.
• Fire watch.
• Hazardous energy.
• Rigging.
• Equipment.
• Training.
• Contractor coordination.

Root Cause Analysis

Root Cause Analysis may identify underlying factors involving:

• Procedures.
• Planning.
• Equipment design.
• Preventive maintenance.
• Training.
• Supervision.
• Contractor coordination.
• Staffing.
• Scheduling.
• Production pressure.
• Corrective-action systems.

Corrective actions should address identified causes rather than simply assigning blame.

Shipyard Safety Inspections

Periodic inspections should evaluate applicable:

• Vessel work areas.
• Confined spaces.
• Scaffolds.
• Ladders.
• Gangways.
• Fire protection.
• Hot Work.
• Electrical systems.
• Rigging.
• Cranes.
• Tools.
• PPE.
• Housekeeping.

Identified deficiencies should be corrected in a timely manner.

Shipyard Safety Training

Employee training should reflect assigned work and hazards.

Depending on responsibilities, training may address:

• Confined and enclosed spaces.
• Hot Work.
• Fire watches.
• Lockout/Tags-plus.
• Welding and cutting.
• Fall protection.
• Scaffolds.
• Rigging.
• Hazard Communication.
• Respiratory protection.
• PPE.
• Emergency procedures.

Employees should not independently perform specialized work until they have received appropriate instruction.

New Employee Orientation

New employees should receive safety orientation before independently performing assigned work.

Orientation may address:

• Vessel access.
• Restricted areas.
• Emergency alarms.
• Hot Work.
• PPE.
• Hazardous energy.
• Housekeeping.
• Incident reporting.

Task-Specific Training

Employees should receive additional instruction before performing unfamiliar or higher-hazard tasks.

Training should reflect:

• Equipment.
• Work location.
• Chemicals.
• Atmospheric hazards.
• Work methods.
• Required controls.

Refresher Training

Refresher or remedial training may be appropriate following:

• Unsafe work practices.
• Procedure violations.
• Equipment changes.
• Process changes.
• Incidents or near misses.
• Identified knowledge gaps.

Safety Meetings

Periodic safety meetings may reinforce safe work practices.

Potential topics include:

• Hot Work.
• Fire watches.
• Confined spaces.
• Lockout/Tags-plus.
• Rigging.
• Falls.
• Welding fumes.
• Housekeeping.
• Contractor coordination.
• Recent incidents.

Recordkeeping

Shipyard employers should maintain occupational safety and health records required for their operations.

Records may include:

• Employee training.
• Injury and illness records.
• Atmospheric testing.
• Competent-person records.
• Marine Chemist certificates.
• Fire-watch records where maintained.
• Lockout/Tags-plus inspections.
• Exposure monitoring.
• Respiratory Protection records.
• Hearing Conservation records.
• Equipment inspections.
• Incident investigations.

Records should be retained according to applicable requirements.

Additional Safety Programs

Depending on shipyard operations and employee exposures, additional programs may be necessary for:

• Shipyard Safety.
• Shipbuilding Safety.
• Ship Repair Safety.
• Shipbreaking Safety.
• Confined & Enclosed Spaces.
• Shipyard Competent Person.
• Hot Work.
• Welding & Cutting.
• Fire Prevention.
• Fire Watch.
• Shipyard Fire Safety.
• Lockout/Tags-Plus.
• Electrical Safety.
• Machine Guarding.
• Scaffolding.
• Fall Protection.
• Ladder Safety.
• Vessel Access.
• Working Over or Near Water.
• Abrasive Blasting.
• Painting & Coating.
• Lead Exposure.
• Hexavalent Chromium.
• Cadmium.
• Asbestos.
• Silica.
• Respiratory Protection.
• Hazard Communication.
• Personal Protective Equipment.
• Hearing Conservation.
• Compressed Gas Cylinders.
• Hand & Power Tools.
• Cranes & Derricks.
• Rigging & Material Handling.
• Hazardous Energy.
• Heat Stress Prevention.
• Housekeeping.
• Emergency Action Plan.
• Contractor Safety.
• Incident Reporting & Investigation.
• Root Cause Analysis.

Programs should be included when the employer’s shipbuilding, ship repair, shipbreaking, fabrication, maintenance, and vessel operations make them applicable.

Building a Shipyard Safety Manual

A useful Shipyard Safety Manual should reflect the employer’s actual work.

A shipbuilding facility may require extensive procedures for steel fabrication, welding and cutting, scaffolds, cranes, rigging, electrical installation, confined spaces, coatings, Hot Work, fire protection, and material handling.

A ship-repair facility may require greater emphasis on vessel access, machinery isolation, Lockout/Tags-plus, tank entry, atmospheric testing, Hot Work, pipe systems, coatings, hazardous materials, electrical work, and contractor coordination.

A shipbreaking operation may require extensive additional procedures for hazardous-material identification, structural dismantling, residual fuel, asbestos, lead, Hot Work, rigging, cranes, falling material, and vessel stability.

A facility specializing in painting, blasting, and preservation may require greater emphasis on abrasive blasting, toxic coatings, solvents, respiratory protection, ventilation, PPE, fire prevention, and exposure monitoring.

The safety manual should therefore be based on the shipyard employment actually performed rather than automatically assigning every maritime program to every employer.

Customized Shipyard Safety Manuals

A Shipyard Safety Manual can be developed around the employer’s shipbuilding, ship repair, shipbreaking, fabrication, welding, confined-space entry, vessel maintenance, scaffolding, crane and rigging operations, coatings, machinery, electrical work, employees, and other occupational hazards.

The finished manual may incorporate applicable programs for Confined and Enclosed Spaces, Hot Work, Shipyard Fire Safety, Lockout/Tags-plus, Welding and Cutting, Scaffolding, Fall Protection, Hazard Communication, Respiratory Protection, PPE, Crane and Rigging Safety, Contractor Safety, Emergency Planning, Incident Investigation, and other hazards associated with shipyard employment.

This provides shipbuilders, ship-repair facilities, shipbreaking operations, vessel-maintenance companies, and other shipyard employers with a practical safety manual organized around the work their employees actually perform.